Process of making building materials



Patented Sept. 1, 1925.

UNITED STATES PATENT. OFFICE;

wmnrnu n. outrun, or DAYTON, 0310.

PROCESS OF MAKING BUILDING IA'I'EBIALB.

1T0 Drawing. Original application filed January 26,1924, Serial'li'o. 688,860. Divided and this application filed October 8, 1924. Serial No. 741,888.

To, all whom it may concern:

Be it known that I, Wmn-IAM'H. CRUME,

a citizen of the United States, residing at Dayton, in the county of Montgomery and 5 State of Ohio, have invented certain new and useful Im rovements in Processes of Making Building aterials, of which the following is a specification. I i

M invention relates to a process of making uilding materials, and is a division of an applicat1on filed by me January 26, 1924, Ser. No. 688,860.

It is the object of my. invention to provide -a process for making a building material which has both strength and heat resisting qualities. It is my object to provide such a process for maklng a material which has tenacity and some de ree of plasticity, so that objects can be naied to it or otherwise attached just as in the case of wood. It is my object to provide such a process for makin adapta le for use in furnaces, fire walls and heat insulating structures. It is my object to rovide such a process for making a ma-' terlal which not only has these qualities, but also can carry the load as well, thus eliminating considerable material which is now used, as in the present state of the art it is necessarto use one material for heat insulation w an another material for carrying the load.-

It is a, further object of my invention to provide a process for making a building material which. will utilize waste products which will require the minimum of materials which must be shipped from given deposits and which may be easily and quickly carried out with standard equipment.

It is my object to provide a process for 4 making a building material which has these qualities and at the same time has the light weight which is essential for shipment. It

is my object to provide light weight because.

of the obvious advantage in the handling of the material in the actual construction of buildings with the result that the work of construction will be materially expedited and cheapened.

It'is my ob'ect to provide a process for I making a buil in materialwhich is of such a character that oor jambs, window frames and the like may be directl' nailed to it without the necessity of woo inserts or the like which are commonly employed in .con-

a material which is fireproof andbon nection with clay, tile and other similar ceramic materials.

For the practice of m invention I select the refuse from .the boi ers after the burnmg o f coal, or slag which is the molten impurities from iron steel, copper and other metals and glass furnaces, which has been subjected to water in molten condition with the result that it has broken up into granuprocess is to structure of the material when finished. The

coke must be removed as the insulating material may be subjected to temperatures as high as 2,000 degrees Fahrenheit. If the coke were presentlit would burn out and .leave large voids, thus greatly decreasing the eflectiveness of the insulating qualities of'the brick. The coke would also tend to disintegrate into powder during the grinding or crushing operation,.thu's greatly'decreasing the strength of the bond formed bythe lime acting on the silica in the mass as hereinafter described i In the description of my invention and the Y claimin thereof, it will be understood that either t e granulated slag or the' clinker, or any other rough granular material which is inert to the usual heat ranges in which the material may be employed may be used, The clinker and slag or a similar material should have this strong granular physical structure, thus' providing a pluralityof interstices or minute passageways for air and a rough clin 'ng surface which will promote t e d ing of Such material should have a silica content the materials with one another.

which also facilitates the bonding action and the imprisoning of air the mass.

Havln v with it eselguhr or any variety of dia-- tomaoeous earth. This material -1s characselected some such material I mix also chemically inert.-

terized by its high silica (SiO content, which ranges from 65 to 95 per cent. There may be present certain lime and magnesia, the lime running up to as much as seven percent. This material is further characterized by the fact that it is susceptible of being very minutely divided, thus being capable of the most intimate mixturewith the slag or. clinker and the lime and being able to penetrate the interstices of the granular material for a purpose to .be hereafter described. Its principal characteristic is its discontinuity because of the contained air, its actual volume usually being about onefifth of the total area occupied, so that it is an efiicient heat insulator for temperatures from 200 to 2,000 degrees Fahrenheit. It-is Its bulk and its light weight, however, make its use profitablefor most purpose and its shipment easy. It also lacks strength so that it cannot be used for supporting any appreciable load.

This finely divided material is intimately mixed with the granular material such as the slag or clinker. The mass is then thoroughly mixed with hydrated lime, sufiicient water being added to give the whole some lasticity; The lime is powdered hydrate, but it also may be usedin a moist hydrated condition or introduced into the mixture as powdered quicklime, allowing the moisture in the mass to hydrate the lime. In such an event the mass is held in containers until the hydration is complete. -Upon getting the massin suitable condition it is formed into building materials such a brick, form desired. 7

The shapes maybe formed either by ressing or tamping or by any other method ibund advisable in the art. It is not necessary, however, to apply greatdpressure and sures can be used. About eighty.

this expense may bee v The shapesso formed are thenlaced m a closed retort and are subjecte to live steam. The preferable pressure of the steam is a proximately 120 pounds and this pressure s ould be continued from four to six hours. It will be understood, however, that both higher and somewhat lower presnnds pressure is the that is e ective. The time in the retort can also be varied by the time indicated in the preferred interval. In treating the slag or clinker in order to insure the proper size of material it is preferable to grind or crush it so that-it will pass through a A" mesh screen prior to mixing with kieselguhr and lime.v

' The effect of the mixing and packing in forms is to coat and surround the particles of the granulated slag with the moistened powders of kieselguhr and lime and tofill the spaces between the larger granular parslabs, blocks andtiles, or any other imprisoning the minute-portions of the air in airtight" cells, thus forming a material having high heat resisting qualities, while the material has great strength due to the slag or clinker content.

In mixing the materials I have found that I may use combinations'ofeighty parts by volume of powdered kieselguhr, twenty parts of granulated slag and twelve to thirty parts of hydrated lime powder, or I may vary the mixture by reducing the pro.- portions of kieselguhr and changing the proportions of the other materials through varying combinations until the kieselguhr is reduced to ten parts by volume, the gran- 1 ulated slag is increased to ninety parts by volume and the hydrated lime powder is present from ten to twenty parts by volume. The increase in the slag, and in referring to slag all similar materials are included, the strength of the material is increased. When .the kieselguhr is comparatively low the product is strong enough to be used in walls and floors of buildings, between studding, and the heat insulation of boilers and furnaces, and can be so employed that they usual additional supporting wall and the extra space it occupies can be eliminated entirely. If the kieselguhr content is increased over 40 percent of the mass, the 7 material will not be sufiiciently strong forcarrying the load bearing walls, but its heat-resisting qualities will be increased.

It will be understood that in the practice of my process and in the composition of my new article of manufacture I do not desire to confine myself to thedetails ofjtemperatures, proportions of mixture, or specific.

material, or methods of handling, as I desire to comprehend within in invention the usual and necessary modi cations which may be found proper in adapting it to vary- Letters Patent of the United'States, is:

1. In a process of manufacturing building material, selecting a relatively strong granular material such as slag, mixin with 1t a diatomaceous earth finely divide mixin in the mass hydrated lime with suffic1ent water to give. plasticity thereto,

'ing conditions and'to the use of "materials shapes forming the mass into shapes and subjecting the shapes in a closed retort to live steam at high pressure.

2. In a process of manufacturing building material, selecting granulated slag or clinker, reducing it to size by grinding or crushing, mixing with it a finely powdered diatomaceous earth such as kieselguhr, mixing with the mass hydrated lime and adding water to give plasticity to the mass, forming the mass into shapes and subjecting the to live steam at high pressure in a closed retort. I

3. In a rocess of manufacturing building material selecting granulated slag 0r clinker, reducing it to size by, grinding or crushing, mixing with it a finely powdered diatomaceous earth such as kieselguhr, mixing with the mass hydrated lime and adding water to give plasticity to the mass, forming the mass into shapes and subjecting the shapes to live steam at high pressure in a closed retort, said steam being maintained at from eightto 120 pounds pressure approximately for aperiod of approximate y four to six hours.

recovering matel 120 pounds and 4. In a roccss of making a buildin material, was ing the residue from coal urning furnaces separating the ash therefrom,

recovering t washing the like, re ucingthe resulting clinkers to size, mixing with kieselguhr, hydrated lime and water, and subjecting the mass to live steam under high pressure in a closed retort.

5. In a process of making a buildin material, was ing the residue from coal urning furnaces separating the ash therefrom,

the coke and removing by the. washing ob'ectionable traces the like, reducing the resulting clinkers to size, mixing with kieselguhr hydrated lime and water, and subjecting the mass to live steam under high pressure in a closed retort, said steam pressure being approxithe period of treatment eing approximately four to six hours.

In testimony whereof, I aflix my signature. Y

e coke and removingby the of acids and H. CRUME.

objectionable traces of acids and 

